TopChiller can design and manufacture all types of Explosion proof chillers for you.

Explosion Proof Chiller-An Ultimate FAQ Guide by TopChiller.

What is an Explosion Proof Chiller?

An Explosion Proof Chiller is a particularly chilling unit installed in environments to achieve cooling in exothermic processes, along with protection against combustible or hazardous substances.

It is primarily used in petroleum, chemical plants, granaries, and laboratories where chances of explosion are present because of flammable substances and hazardous environments.

A screw and scroll design, available in water and air-cooled models, is the most common type used in the industry. Its flame-retardant features, sturdy construction, and multiple safety features make it suitable to be used around hazardous or combustible materials.

A durable evaporator, low noise compressor, and a powerful condenser are the major components that work in coordination to achieve its cooling effect.

Unlike the standard chiller, it is manufactured according to the safety rules and guidelines provided by the National Fire Protection Agency and National Electric Code (for electrical parameters.

Explosion Proof Chiller is equipped with sealed wiring, which supplies maximum protection to the air from sparks that can be a reason for the ignition of vapors, resulting in an explosion.

Explosion Proof Chiller Fabricated by TopChiller

What are the Main Features of an Explosion Proof Chiller?

Some notable features that are helpful in the high-performance and durable structure of an Explosion Proof Chiller are:

• The compressors and the threaded tube heat exchanger are high-quality and efficient.
• The water pipeline, as well as a tank, are manufactured of SUS304 stainless steel.
• A primary remote switch enables you to keep the temperature, pressure, and other conditions under control through remote communication.
• It can be controlled by either a microcomputer or PLC.
• Precisely designed for chemical and other flammable and explosive sites.
• The refrigerant can be chosen from a wide range of options.
• Less noise, high heat flow, and powerful output.
• A high-strength welding frame and outdoor spray paint are used.
• The evaporator can be chosen from various types, including stainless steel plate type, shell and tube, and coil types. It can also be selected from acid and alkali resistant, and anticorrosive varieties.

What are the Basic Components of an Explosion Proof Chiller?

Some essential parts that work in coordination to provide the effect of the Explosion Proof Chiller are mentioned below:

Compressor

It has an explosion-proof electrical cabinet, is highly corrosion-resistant, and is suited for a challenging working environment.

The strengthened cabinet has significantly increased the unit’s service life, which is a significant benefit. Moreover, the performance is excellent, and noise levels from the compressor are minimal.

Evaporator

An inner and outer threaded copper tube is used to construct the evaporator, and the copper tube provides a beneficial cooling effect.

The evaporator barrel is insulated with a thickness of a PE insulation board that is 26mm. Because there is less condensation, there is minimal cold loss.

Condenser

The condenser is fitted with effective cross-seam fins and female threaded copper tubes for maximum heat transfer effectiveness and durability.

Controls

The Explosion Proof Chiller control unit keeps track of the different aspects of the unit’s productivity and makes improvements if needed.

To avoid damage to the unit, the control unit can produce alarms for the safe shutdown. Remote control and tracking of the chiller are generally possible because of the BMS connections.

Power Unit

A highly efficient power unit installed in the chiller connected to the plant room wall with power cables.

The power unit controls the course of electricity to the unit. Circuit breakers, speed controller, starter, and power monitoring gear are also included in it.

Explosion Proof Chiller Centrifugal Compressor Inside View

What are the Applications of an Explosion Proof Chiller?

An Explosion Proof Chiller has multiple applications where cooling and protection from any sort of explosion is required; some of them are explained below:

Sample or Process Analyzers

Workers can determine the chemical composition of various substances using sampling or process analyzers.

Explosion safety in the sample analysis sections might save lives since the components are unknown and potentially harmful elements.

Granaries

Flour is a highly explosive substance. A spark is all that is needed to ignite the tiny particles in the atmosphere.

Silos and granaries require explosion-proof construction for this reason.

Laboratories

Lab workers’ health and safety depend on proper ventilation. The need for fire prevention and explosion proofing is not to be overlooked.

In volatile environments, you need particular components to prevent stray sparks from igniting flammable vapors or gases.

Chemical Plants

Chemical factories can produce or store combustible materials. This is why a chemical plant will require an Explosion Proof Chiller even in the storage areas.

Cooling Flammable Liquids

Vapors from combustible liquids may be hazardous, especially if they catch fire. An Explosion Proof Chiller is preferably required for these gases. The only class I, Division 2 units, would be needed if the fluids stay sealed.

A class I, division 1-approved unit is essential in any area where employees transfer fluids to some other vessel or have flammable materials exposed at any time.

Offshore Oil Rigs

Everything is riskier in an offshore setting because of the inherent danger of the environment.

If space isn’t a factor, the remote position in the middle of the water, distant from fire departments, requires an explosion-proof cooling unit.

There is also the risk of oil rigs having exposed oil that might evaporate and create a hazardous condition if a spark occurs. The crew’s living and working environments are kept secure and comfortable by installing this chiller.

Explosion Proof Chiller Applications

How Does an Explosion Proof Chiller Work?

The working of an Explosion Proof Chiller is explained in the given steps:

1. At the start of the process, the refrigerant is mixed with a gas and a liquid to be used.
2. Refrigerant is cycled through the parts of the unit to transfer heat from the processed coolant and out to the atmosphere.
3. The evaporator heats the refrigerant, transforming it from a liquid to a gas with low pressure.
4. The low pressure gas is then sent to the compressor, where high pressure reduces the refrigerant volume. The high pressure also helps in propelling the particles to the condenser.
5. Water or air can be used in the condenser to cool down the heated refrigerant.
6. Finally, the coolant releases its heat and returns to a liquid state. A regulator valve controls how much chilled refrigerant enters the evaporator to restart the cycle.
7. When this liquid passes through the regulator valve, it is high pressure.
8. This high-pressure refrigerant again changes into liquid and repeats the refrigeration cycle by entering the evaporator.

What are the Key Advantages of Using an Explosion Proof Chiller?

Here is a list of multiple advantages of using an Explosion Proof Chiller for your industry:

• The best protection against hazardous substances
• It decreases the chance of a spark from a machine igniting explosive or flammable kinds of stuff
• Efficient cooling in high-temperature processes
• Simple maintenance
• Trouble-free usage
• Fast cooling action
• Enhanced cooling effect in contrast to standard chiller

What are the Common Types of an Explosion Proof Chiller?

Based on differences in the design, components, and primary source to complete the cooling effect, an explosion-proof cooling system is divided into the following categories:

Explosion Proof Scroll Chiller

Scroll compressor chiller systems have an overlapping spiraling arrangement in the compressors.

When the warm, reduced pressure refrigerant goes through them, the scrolls increase their pressure.

This is done until it reaches the requisite high-pressure, heated condition at the exit.

Explosion Proof Screw Chiller

A screw chiller’s compressor utilizes either one or two screws to compress the refrigerant to a high-pressure condition.

Air Cooled Chiller

The high-pressure, heated refrigerant is sent via a condenser, which discharges air across the tubes present within these air-cooled chilling systems.

The refrigerant’s heat is removed by air, traveling to the evaporator.

Water Cooled Chiller

Water cools down condensers that use water to eliminate heat from the refrigerant.

The heat from the refrigerant travels to the chilled water, which can later go to the cooling tower and dissipate the heat to the environment.

How is an Explosion Proof Chiller Different from the Standard Chiller?

The safety and protection of the components distinguish an Explosion Proof Chiller from the regular chiller. The cooling function and refrigeration unit are almost the same for all types.

Wires are routed via an airtight conduit, and motor connector cabinets are also airtight. Combustible gas is further prevented from accessing the system via seals.

The unit’s construction makes it possible to install it even in potentially hazardous locations by sealing the electrical components entirely.

Nitrogen purge systems are also available in specific units (where permitted), which pressurize the whole electrical control panel and conduit to keep away any outside air.

How is an Explosion Proof Chiller Useful for your Petrochemical Plant?

The Explosion Proof Chiller is useful to differentiate a petrochemical factory from a refinery. The first generates compounds from petroleum, while the second refines crude oil.

Both are exposed to potentially hazardous substances and deal with very high temperature processes. In many cases, petrochemicals, including gasoline, are desirable because of their capacity to burn.

Petrochemical plants are also at risk of catching fire because of gasoline.

The NEC requires several petrochemical plants to have an Explosion Proof Chiller to protect them from the severe hazardous effects of these combustible materials.

Why is a Drier Filter Installed in an Explosion Proof Chiller?

A drier filter of an Explosion Proof Chiller has two objectives:

• First, it serves as a physical impurity filtration device to remove system impurities such as water vapors.

• Secondly, it serves to keep out any potentially harmful physical impurities from entering it.

So the main benefit that a drier filter can achieve is to keep away contaminants and impurities, which can be responsible for various problems if they enter the unit.

Explosion Proof Chiller Filter Drier

What is the Role of a PLC Controller in an Explosion Proof Chiller?

Remote observation and management are possible with the help of a sophisticated PLC system.

An easy-to-use interface, low failure rates, a high safety factor, and an easy setup process are some of the main benefits achieved by this system.

This control system may handle most of the Explosion Proof Chiller functions. It is majorly used to control the temperature.

The code is also displayed on the screen if there is a problem with the unit. The best thing is that this PLC system is super easy and friendly for any user to operate.

How to Protect your Explosion Proof Chiller During Harsh Weather?

Your Explosion Proof Chiller should be protected from the elements by following these precautions:

• For the base to function correctly during storms, the unit should be appropriately installed on the foundation. There must be no exposed or loosened nut or bolt at any time.
• No panel screw or fastener should be loose or missing from any panels.
• Emergency conditions necessitate the presence of all the required safety equipment.

What are the Safety Devices Present in an Explosion Proof Chiller?

An Explosion Proof Chiller can undergo harm and damage due to several fluctuations, which can be prevented by the presence of the giving safety devices:

• Circuit breakers and fuses for managing the current flow
• Alarm system for the fire
• The compressor’s thermal overload safety relay
• Anti-freeze thermostat
• Switches for both high and low pressure
• Alarm for excessive heat
• A sight glass for monitoring the moisture
• Compressor flow switch
• Low-refrigerant warning
• Switch for oil safety
• Cables and wires that are resistant to fire

Explosion Proof Chiller Circuit Breakers

How to Properly Size Explosion Proof Chiller for your Industry?

To determine the proper size of an Explosion Proof Chiller, you must first select the desired temperature drop and the required flow rate.

The necessary drop in temperature equals the difference between the temperature of the fluid entering it and the temperature of the chilled liquid, expressed in Fahrenheit.

This means that if the water/fluid you’re working with has a temperature of 72 degrees Fahrenheit, you need it to be 50 degrees. Here 72 – 50 = 22 would be the drop in temperature.

To get the total quantity of gallons/hour, multiply the flow rate by 60. Now use these gallons / hr. by 8.33, and the temperature drops. The BTUs / hr. may be calculated using this formula.

For best results, avoid selecting a unit that is either tiny or too big. To get a specific temperature it can’t achieve, your system will run nonstop and never shut down.

This puts undue strain on the system, reducing its lifespan and necessitating more frequent maintenance. Keep in mind that you don’t want to overstuff a unit.

An oversized Explosion Proof Chiller might be challenging to install and cost you more money for that cooling which you’ll never use.

In the case of selecting this unit, the question of size always remains crucial. To accelerate the purchase process, have an estimate of how much cooling capacity you’ll need.

What are the Specific Installation Precautions for your Explosion Proof Chiller?

The whole installation process for the Explosion Proof Chiller must adhere to all applicable regulations set by NEC.

The unit’s electrical wires must be protected from sparks by encasing them in conduits.

Its installation may necessitate flexible coverings, and the code places rigorous restrictions on the types of permissible covers. Any fittings or boxes used in a class or division must be marked with an approved label for that class or division.

Such as in class I, Division 1 sites where boxes should be explosion-proof and marked accordingly. Although manufacturers strongly encourage them, the NEC does not mandate explosion-proof containers or connections in division 2 regions.

The NEC imposes further limits on conduit seals depending on whether the unit is installed in division 1 or division 2 sites.

There is a requirement for conduit sealing at both points where conduit enters.

The installation of an Explosion Proof Chiller in a class I site shall only be performed by a professional.

It is just as harmful to use it in the wrong place as having it built incorrectly. Both have the potential to put your employees in danger or result in hefty losses for your company.

This is why it is critical to check that you’ve got the correct unit and that it has been fitted correctly.

Explosion Proof Chiller Installation

What are the Safety Tips When Using your Explosion Proof Chiller?

While operating your Explosion Proof Chiller, given safety tips are essential not only for the user’s protection but also for the protection of the unit:

• Read all manufacturer’s warnings, directions, and precautions presented in the guidance manual
• In case of an emergency, keep a fire extinguisher near your Explosion Proof Chiller. Everyone involved must know how to use a fire extinguisher, and it must be in perfect condition.
• All the cables should be routed and secured appropriately.
• The protective covering must surround all moving parts.
• Training of the operators for safe equipment usage is essential.
• Evaluate your automatic shutoff system every 2 – 3 years.

Wear PPE Before Operating your Explosion Proof Chiller

How to Troubleshoot your Explosion Proof Chiller?

The failure of the compressor of an Explosion Proof Chiller is its most prominent problem, which can occur due to the following reasons:

Compressor Overload

The operating load and the current load in the compressor are very high. This may happen due to the high temperature of the cooling water or due to the presence of a non-condensing gas in this system.

The possible solutions are to adjust the cooling water temperature and remove any non-condensing refrigerant present in the compressor.

Electrical Failure

Any failure in the electrical system of this equipment can fail its compressor.

Multiple possible reasons for this problem include a reduced three-phase supply voltage, a damaged AC contractor, or a large contact current.

The best solution is to call for an expert technician to resolve your unit’s electrical problems and save it from more extensive damage.

Overheating Protection or Moisture Damage

A compressor failure is often a result of damage to the overheating protection system or moisture accumulation.

An overheating failure occurs when the overheating relay is faulty. This will cause a problem in turning on your system.

Here it would be best if you got your overheating protection device fixed or replaced so that you can save the compressor from failure.

Ventilation Problem

Sufficient ventilation is an essential factor for the average working of an Explosion Proof Chiller.

If you install this equipment at a location where inadequate ventilation is provided, the compressor will start overheating.

Also, blockage around the compressor due to the accumulation of dirt and debris can result in poor ventilation.

So, it is crucial to ensure proper cleaning and ventilation for your compressor.

Explosion Proof Chiller Troubleshooting

How to Improve the Efficiency of your Explosion Proof Chiller?

The following factors can help to enhance the efficiency of your Explosion Proof Chiller:

• Any gauges or similar equipment requiring calibrating or adjustment must be completed on time and without fail.
• Keep a daily log to keep track of your activities.
• Do a thorough dusting and cleaning every day.
• Only a qualified operator shall use this device.

How to Choose the Best Explosion Proof Chiller for your Industry?

To choose the most suitable Explosion Proof Chiller for your usage, it is essential to consider the following factors:

• The primary thing is to understand the perfect size suitable for your space.
• Another critical parameter is considering the required cooling capacity suitable for your application.
• It is also essential to know about the division or type of Explosion Proof Chiller you need.
• Also, ensure every equipment component’s presence and proper working to complete its function.

How to Add Refrigerant and Oil to your Explosion Proof Chiller?

Refrigerant

To add refrigerant to your Explosion Proof Chiller correctly, follow the given tips and tricks:

1. The very first thing is to close all the valves of your system.
2. Now, it is suggested to establish a connection between low and high pressure using a vacuum pump.
3. Use the vacuum pump to empty your unit.
4. Now, find the type of refrigerant you need to fill in your system.
5. Calculate the amount of refrigerant which will be sufficient for your application.
6. Make sure to add the refrigerant slowly.
7. Consider the instruction manual to get into more details about the quantity of refrigerant you will need and further instructions.

Oil

The primary purpose of adding oil to your Explosion Proof Chiller is to reduce the friction between the different parts of the compressor.

Before lubricating your compressor, consider your guidance manual to determine the quantity of oil sufficient. You can continuously monitor the oil levels with the help of the sight glass present on the condenser.

Very high or deficient levels can be responsible for significant damage to your system; therefore, always add the required amount.

Explosion Proof Chiller Refrigerant Filling